Alternator - Life Fitness Lifecycle 3500 Series Service Manual

Lifecycle 3500, 4500, 5500 Series Exercise Bikes
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How To...REMOVE AND REPLACE THE
ALTERNATOR CONTROL BOARD / RESISTOR
Tools Required: 3/8" wrench, 1/4" wrench, 5/16" wrench, pliers, scissors
Step 1
Remove the HOUSING (See "How To. . .").
Step 2
Remove the DISPLAY CONSOLE (See "How To. . .").
Step 3
Locate DISPLAY WIRE HARNESS slot in FRAME, gently pull out the DISPLAY WIRE HARNESS from the FRAME.
NOTE: BE CAREFUL WHEN FEEDING THE WIRE HARNESS THROUGH THE FRAME.
THE CONNECTOR BLOCK MAY CATCH ON THE WELDNUTS OR FRAME.
Step 4
With a pair of scissors, carefully cut the two TIE WRAPS on the ALTERNATOR BRACKET.
Step 5
Remove the two POSITIVE RED WIRES from their POSTS on the ALTERNATOR. With a 1/4" wrench, remove the
two NUTS securing the BLACK FIELD WIRE and the WHITE WIRE. With a 5/16" wrench, remove the
REGULATOR TERMINAL NUT and the GROUND TERMINAL NUT.
Step 6
With a 3/8" wrench, remove the RESISTOR
NUT and WASHER that secure the RESISTOR
to the ALTERNATOR BRACKET.
Step 7
Use pliers to carefully collapse the top of the
four STANDOFFS which secure the worn
ALTERNATOR CONTROL BOARD to the
ALTERNATOR BRACKET.
WARNING: DO NOT BEND OR BREAK THE
STANDOFFS. THEY WILL BE NEEDED
WHEN
INSTALLING THE NEW ALTERNATOR
CONTROL BOARD.
Step 8
Remove the faulty ALTERNATOR CONTROL
BOARD and the two WIRE HARNESSES from
the FRAME. Position the new BOARD in its
place.
Step 9
Reverse Steps 1 through 6 to return all parts
back into place.
Tighten parts to the following specifications:
Resistor Bolt 12-15 in. lbs.
2